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3110-01 TCU
1) CONNECTOR INFORMATION

2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

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(3) CIRCUIT DESCRIPTION

A. ION (BTRA) M74 4WD AUTOMATIC TRANSMISSION ▶ TCM OUTPUTS
The ION (BTR) Four Speed Automatic Transmission is an electronically controlled overdrive The outputs from the TCM are supplied to the compo-nents described below;
four speed unit with a lock-up torque converter. - Solenoids
The lock-up torque converter results in lower engine speeds at cruise and eliminates - Mode Indicator Light
unnecessary slippage.
These features benefit the customer through improved fuel economy and noise reduction. ▷ Solenoids
Of primary significance is the Transmission Control Mo-dule (TCM) which is a microprocessor
The TCM controls seven solenoids. Solenoids 1 to 6 (S1 to S6) are mounted in the valve
based control system.
body, while Solenoid 7 (S7) is mounted in the pump cover.
Shift scheduling is highly flexible, and several indepen-dent schedules are programmed
depending on the ve-hicle.
Solenoid Logic for Static Gear States
Typically the NORMAL schedule is used to maximize fuel economy and driveability, and a
POWER schedule is used to maximize performance.
WINTER schedule is used to facilitate starting in second gear.

B. Communication systems

▶ CAN

The Controller Area Network (CAN) connects various control modules by using a twisted
pair of wires, to share common information. This results in a reduction of sensors and
wiring. TCM obtains the actual engine speed and throttle position, vehicle speed and - Solenoid 1 and 2: S1 and S2 are normally open ON/ OFF solenoids that set the
accelerator position etc. from ECM via CAN without any additional sensors. selected gear.
These solenoids determine static gear position by operating the shift valves.
Note that S1 and S2 solenoids also send signal pressure to allow or prohibit rear band
▶ K-Line - Solenoid 3 and 4: S3 and S4 are normally open ON/ OFF solenoids that combine to
The K-line is typically used for obtaining diagnostic information from the TCM. control shift quality and sequencing. S3 switches the clutch regulator valve OFF or
A scan tool with a special interface is connected to the TCM via Data Link Connector ON. S4 switches the front band regulator valve OFF or ON. S5 also provides the
(DLC) and all current faults, stored faults, runtime parameters are then available. signal pressure for the converter clutch regulator valve.
The stored trouble codes can also be cleared by scan tool. - Solenoid 5: S5 is a variable pressure solenoid that ramps the pressure during gear
changes. This solenoid provides the signal pressure to the clutch and band regulator,
thereby controlling the shift pressures.
S5 also provides the signal pressure for the converter clutch regulator valve.
- Solenoid 6: S6 is a normally open ON/OFF solenoid that sets the high/low level of line
pressure. Solenoid OFF gives high pressure.
- Solenoid 7: S7 is a normally open ON/OFF solenoid that controls the application of
the converter clutch.
Solenoid ON activates the clutch.

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C. CONTROL SYSTEMS F. PROCESSING LOGIC

BTRA M74 4WD automatic transmission consists of two control systems. One is the Shift schedule and calibration information is stored in an Erasable Programmable Read Only
electronic control system that monitors vehicle parameters and adjusts the transmission Memory (EPROM).
performance. Another is the hydraulic control system that implements the commands of the Throttle input calibration constants and the diagnostics information are stored in Electrically
electronic control system commands. Erasable Programmable Read Only Memory (EEPROM) that retains the memory even when
power to the TCM is disconnected.
D. ELECTRONIC CONTROL SYSTEM TCM continuously monitors the input values and uses these, via the shift schedule, to
determine the required gear state.
The electronic control system comprises of sensors, a TCM and seven solenoids. The TCM
At the same time it monitors, via the solenoid outputs, the current gear state, whenever the
reads the inputs and activates the outputs according to values stored in Read Only Memory
input conditions change such that the required gear state is different to the current gear state,
(ROM).
the TCM initiates a gear shift to bring the two states back into line.
The TCM controls the hydraulic control system. This control is via the hydraulic valve body,
Once the TCM has determined the type of gearshift required the TCM accesses the shift
which contains seven electromagnetic solenoids.
logic, estimates the engine torque output, adjusts the variable pressure solenoid ramp
Six of the seven solenoids are used to control the line pressure, operate the shift valves and
pressure then executes the shift.
the torque converter lock-up clutch, and to turn ON and OFF the two regulator valves that
The TCM continuously monitors every input and output circuit for short or open circuits and
control the shift feel.
operating range.
The seventh solenoid is the proportional or Variable Pressure Solenoid (VPS) which works
When a failure or abnormal operation is detected the TCM records the condition code in the
with the two regulator valves to control shift feel.
diagnostics memory and implements a Limp Home Mode (LHM).
The actual limp home mode used depends upon the fail-ure detected with the object to
E. TRANSMISSION CONTROL MODULE (TCM) maintain maximum driveability without damaging the transmission.
The TCM is an in-vehicle micro-processor based trans-mission management system. In general input failures are handled by providing a default value.
It is mounted under the driver’s side front seat in the vehicle cabin. Output failures, which are capable of damaging the transmission, result in full limp mode
The TCM contains: giving only third or fourth gear and reverse. For further details of limp modes and memory
retention refer to the Diagnostic Trouble Code Diagnosis Section.
- Processing logic circuits which include a central mi-croprocessor controller and a back-up The TCM is designed to operate at ambient temperatures between - 40 and 85°C (- 40
memory system. and 185°F).
- Input circuits. It is also protected against electrical noise and voltage spikes, however all the usual
- Output circuits which control external devices such as the Variable Pressure Solenoid precautions should be observed, for example when arc welding or jump starting.
(VPS) driver, On/Off
solenoid drivers, a diagnostics output and the driving mode indicator light.

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G. TCM INPUTS
To function correctly, the TCM requires engine speed, vehicle speed, transmission fluid
temperature, throttle position, gear position and Kickdown Switch inputs to determine the
variable pressure solenoid current ramp and on/off solenoid states.
This ensures the correct gear selection and shift feel for all driving conditions.
The inputs required by the TCM are as follows;

▶ Engine Speed
The engine speed signal is derived from the Controller Area Network (CAN) via Engine
Control Module (ECM).

▶ Vehicle Speed
The vehicle speed sensor, which is located in the transfer case, sends the output shaft
speed signal to the Engine Control Module (ECM).
The information is then transferred to the TCM via the CAN.

▶ Transmission Fluid Temperature

The transmission fluid temperature sensor is a thermistor located in the solenoid wiring
loom within the valve body of the transmission.
This sensor is a typical Negative Temperature Coefficient (NTC) resistor with low
temperatures producing a high resistance and high temperatures producing a low
resistance.
If the transmission fluid temperature exceeds 135°C (275°F), the TCM will impose
converter lock-up at lower vehicle speeds and in some vehicles flashes the mode indicator
light.
This results in maximum oil flow through the external oil cooler and eliminates slippage in
the
torque converter.
Both these actions combine to reduce the oil temperature in the transmission.

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▶ Pin No. Codes and colors in Solenoid Loom ▶ ACCELERATOR PEDAL SENSOR

Connector

The accelerator pedal sensor changes the position of the accelerator pedal into the electric
signal and sends the conditions that a driver requires to the engine ECU.
▶ GEAR POSITION SENSOR It consists of two sensors.
The gear position sensor is incorporated in the inhibitor switch mounted on the side of the The signals from No.1 sensor (ACC 1) is the element to determine the amount of the fuel
transmission case. injection and injection timing while the signals from No. 2 sensor (ACC 2) determines if the
The gear position sensor is a multi-function switch providing three functions; signals from No. 1 sensor is correct by comparing them with its own signal values.
The transferred values from accelerator pedal sensors to ECU is sent to TCU via the CAN
communication lines. The TCU changes the gear by determining the shift timing according
to these values.

- Inhibit starting of the vehicle when the shift lever is in a position other than Park or
Neutral
- Illuminate the reverse lamps when Reverse is selected
- Indicate to the TCM which lever position has been selected by way of a varying
resistance.
Readings for Resistance / Shift Lever Positions

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H. DIAGNOSTIC TROUBLE CODES

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3740-01 A/T SHIFT LOCK

1) CONNECTOR INFORMATION

2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

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3410-01 TCCU
1) CONNECTOR INFORMATION

2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

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3) CIRCUIT DESCRIPTION
(1) OVERVIEW (2) TCCU PIN NUMBERS AND DESCRIPTION
The part time transfer case achieves direct connection from the power of the rear wheels to
the power of the front wheels by the lock up hub when selecting 4WD "HIGH" and the power
is supplied by the sealant chain in the transfer case.
The simple operation of switches on instrument panel allows to shift between “2H” and
“4H” easily while driving.
The warning lamp warns the driver when the system is defective.

The 4WD system integrated in KYRON does not have big difference in comparison to the
conventional part time transfer case, but the changes in comparison to the conventional
transfer case are as follows

- Delete 4L (LOW 4WD)

· Delete the planetary gear, reduction hub and shift fork.
· Add the coupling according to the deletion of the planetary gear.
- No additional coding is required when replacing TCCU.
- Delete the devices (tone wheel, wiring etc.) related to the speed sensor in the transfer
case.
This system receives the speed signals from ABS/ESP HECU or instrument panel
(for non-ABS vehicle(Note)) through the CAN communication.
- Delete the pin related to the speed sensor from TCCU pins.
- Change the transfer case wiring connector from No.4 pin to No.1 pin. (Power and
ground related to the speed sensor)
The new TCCU is available to install on the vehicle with the conventional DI engine
part time TCCU.

▶ SPECIFICATIONS

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▶ POSITION ENCODER ▷ Motor Controls

- TCCU operates the shift motor until it reads the required position code.
If it detects the faulty code, the system is operated with the compensation mode.
- Once the shift operation is started, it is completed regardless of the ignition power.
If there are not operating signals from the position sensor, the shifting failure occurs
due to timeout.
This failure appears when the shifting time between 2H and 4H is delayed over 5
seconds compared to normal shift.
- Once the shifting time exceeds the specified time, TCCU cannot properly supply the
voltage to shift motor and is operated in compensation mode.
- Even though the system recognizes a fault before motor starts, it is considered as a
▶ OPERATION fault.
- Motor stops operation when it reaches target range.
▷ TCCU initialization and operation
- TCCU sends relevant data to meter cluster via CAN to diagnose and check the ▷ Synchronization
indicators when the ignition switch is turned to ON. At this time, the 4WD indicators
Synchronization occurs during shifting from 2WD (2H) to 4WD (4H).
(4WD LOW and 4WD HIGH) come on for 0.6 seconds.
The synchronizer clutch and the hub solenoid are controlled during the synchronization
- TCCU starts diagnosis by operating clutch coil and hub solenoid for 1.5 seconds.
as follows:
- The shift operation is controlled to move only toward selector switch position if the
selector switch position is not met with shift motor position code when the ignition - The clutch coil operates when the selector changes from 2H to 4H.
switch is turned to ON. - The shift motor moves in 4H mode.
- The locking hub solenoid starts its operation 4 seconds after shifted to 4H.
- The clutch coil stops its operation 5 seconds after the hub solenoid is activated.
▷ Drive Mode Change
The shift operation is only allowed when some conditions are satisfied.
▷ Compensation
These shift conditions should be satisfied for 2 seconds before starting motor.
The motor stops when the encoder related to troubles are detected during shift
The motor has three seconds of delay at its initial operation to do trouble diagnosis.
operation.
Once the motor starts, the shift conditions are no longer checked.
It moves toward LOWHIGH direction for 5 seconds so that the motor is not left in
unidentified position.
▷ Shift conditions are as follows:
- Normal battery voltage and shift motor for all gears
- 2H and 4H shifts has nothing to do with the vehicle speed, the “N” position in
the automatic transmission or the clutch signal.

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(3) TROUBLE DIAGNOSIS TEST (4) SELF-DIAGNOSIS TEST

A. Shift Motor Test - TCCU detects the transfer case
- Check short and open circuit before and during shifting. systems malfunctions and indicates
- When the system detects a fault in the shift motor for over 1 second, the “4WD malfunctioning part (s) through
CHECK” warning lamp flickering of the “4WD CHECK”
- comes on and a trouble code is stored into memory. indicator.
- The trouble code being detected in shift motor during its operation is defined as timeout. Connect Scan-I to the diagnostic
The trouble code for the shift motor can be erased by using scanner. connector located under the steering
wheel.
B. Transmission System Timeout Test
- The shift timeout occurs when the position sensor of shift motor does not try to operate,
which happens 1.5 seconds after completion of 2H-4H shift.
- When the timeout occurs, TCCU cuts off the voltage to shift motor and operates the
compensation mode. - The transfer case system is
malfunctioning when:
C. Position Encoder Test
· The “4WD CHECK” indicator
- When the system detects a fault in shift motor for over 1 second, the “4WD remains on after 0.6 second after
CHECK” warning lamp comes on and the trouble code is stored into the memory. turning the ignition switch ON.
- The position encoder fault can be divided into a general encoder fault and short to · The “4WD CHECK” indicator
ground of position encoder circuit. continuously comes on during
· General encoder fault: Invalid position code input driving.
· Short to ground of position encoder circuit: Ground for encoder circuit
- Connect Scan-I to the diagnostic
D. Clutch Coil Test connector and read the defective
code with the ignition switch “ON”
- Check the clutch coil for open and short circuit. (refer to Diagnosis Table).
- When the system detects a fault in shift motor for over 0.8 seconds, the “4WD - After repairing, erase the defective
CHECK” warning lamp comes on and the trouble code is stored into the memory. code stored in TCCU.

E. Compensation
Before replacing the malfunction
- The motor stops when the encoder related troubles are detected during shift operation. parts with defective code, check the
It moves toward LOW-HIGH direction for 5 seconds so that the motor is not left in wires and connectors for looseness
unrecognized position. and open circuit.

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(5) DIAGNOSTIC TROUBLE CODE

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4892-01 ABS/ESP
1) W/SPEED SENSOR, STOP LAMP SW, DIAGNOSIS, WARNING
LAMP (ABS/ESP) (1) CONNECTOR INFORMATION

(2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

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2) PRESSURE SENSOR, S.W.A SENSOR, SENSOR CLUSTER,

ESP OFF SW, HDC (1) CONNECTOR INFORMATION

(2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

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(3) CIRCUIT DESCRIPTION D. SWAS : STEERING WHEEL ANGLE SENSOR

A. ABS COMPONENTS The steering wheel angle sensor is located between clock spring and multifunction switch.
This sensor is used for recognition of driver’s intends.
Newly introduced ABS has a different shape of integrated hydraulic modulator and HECU
If the sensor is replaced with new one, it can detect the neutral position after the vehicle is
(Hydraulic and Electronic Control Unit) compared to existing ABS.
moving over 20 km/h for more than 5 seconds.
And, the wheel speed sensor uses different method to detect wheel speed.
The basic function of the ABS that maintains the vehicle stability by controlling the steerability
of the vehicle when braking has not been changed.

B. ACTIVE WHEEL SPEED SENSOR

The speed sensor used in traditional ABS is made of permanent magnet and transmits the
output voltage that changes as the wheel rotor rotates to the HECU system.
New wheel speed sensor detects the wheel speed through the current value that depends on
the resistance that changes according to the magnetic field by using four resisters and
supplying the 12 V power supply to the sensor.

▶ Specifications

E. HDC (Hill Descent Control) SYSTEM

When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed
condition given in step (4).

▶ When the slope level is between 10% and 20% during the HDC operation

When depressing the accelerator pedal or brake pedal, HDC system is changed to
stand-by mode.
When depressing the accelerator pedal again, HDC starts its operation again.
C. HBA (HYDRAULIC BRAKE ASSIST SYSTEM)
Therefore, drivers can control the vehicle speed to a desired level by operating the
HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the accelerator pedal.
driver applies the brake fast, but not with sufficient pressure, which leads to dangerously long
▶ When the slope level exceeds 20% during the HDC operation
braking distance.
ECU recognizes the attempt at full braking and transmits the signal calling for full brake When depressing the accelerator pedal, HDC system is changed to stand-by mode.
pressure from the hydraulic booster. When depressing the brake pedal, HDC continues its operation and the braking power is
An inexperienced, elderly or physically weak driver may suffer from the accident by not fully increased.
pressing the brake pedal when hard braking is required under emergency. In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but
The HBA System increases the braking force under urgent situations to enhance the inputted this is a normal condition due to HDC operation.
braking force from the driver.

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F. INPUT/OUTPUT SIGNALS FOR HDC OPERATION G. OPERATION OF HDC INDICATOR CONTROLLER

This table describes the coming-on and blinking mode of HDC indicator according to the HDC
switch operation(ON/OFF).
The HDC indicator on the instrument panel has two modes; green (function lamp) and red
(warning lamp).
The HDC switch is a push & self return type switch ? when you press it once, it starts to
operate and when you press it again, it stops the operation.

H. ESP (ELECTRONIC STABILITY PROGRAM)

ESP (Electronic Stability Program) recognizes critical driving conditions, such as panic
reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and
engine control intervention with no need for actuating the brake.
This system is developed to help the driver avoid the danger of losing the control of the
vehicle stability due to under-steering or over-steering during cornering.

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I. SENSOR CLUSTER (YAW RATE SENSOR + LATERAL ACCELERATION SENSOR + L. ESP SYSTEM CANCELLATION USING THE ESP OFF SWITCH
LONGITUDINAL ACCELERATION SENSOR) When the ESP switch at the center switch panel is pushed (for over approximately 150 ms),
the ESP system will be cancelled and the vehicle will be driven regardless of the output
values from the corresponding sensors.
Then, the ESP warning lamp on the instrument panel comes on.

M. RESUMING THE ESP SYSTEM BY USING THE ESP OFF SWITCH

The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off
when the ESP switch at the center switch panel is pushed (for over approximately 150 ms)
J. PRESSURE SENSOR
while the ESP system is not operating.
▶ Specificatons

K. ESP WARNING LAMP BLINKING IN CONTROL

ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain
limitation, a beep sounds to warn the driver.
The ESP warning lamp goes off when ESP function is deactivated.
Even when the ESP is operated for a very short period of time, the ESP warning lamp blinks
minimum of 4 times every 175 milliseconds and the buzzer sounds for at least 1.4 seconds
with 100 ms interval.

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